Catalyst for lower alkane conversion

Abstract

A methed for converting a feedstock alkane containing from 1 to 3 carbon atoms to a higher molecular weight hydrocarbon comprising contacting a feedstock with an oxygen-containing gas in the presence of a catalytic composition is disclosed. The catalytic composition includes a Group IA metal, a Group IIA metal and a third component, the precursor of which is a sol such as an aqueous suspension of a metal such as aluminum, silicon, titanium, zinc, zirconium, cadmium or tin with which the other components of the composition are throughly dispersed.

What is claimed is: 
     
       1. A composition prepared according to a method comprising the steps of: thoroughly dispersing in an aqueous medium and mixture comprising a first material comprising a Group IA metal, a second material comprising a Group IIA metal, and a sol comprising an aqueous suspension of a compound of an element selected from the group consisting of aluminum, silicon, titanium, zinc, zirconium, cadmium and tin to form a slurry, with the combination of said Group IA and said Group IIA metals being selected to be stable at oxidative coupling reaction conditions, and   drying said slurry to evaporate substantially all of said aqueous medium and leaving behind a substantially dry solid material wherein said Group IA metal and said Group IIA metal are in an atomic ratio of about 0.5:1 to about 2:1 and said metal of said sol comprises about 1 wt. % to about 30 wt. % of said dry material.   
     
     
       2. The composition of claim 1 wherein said sol comprises alumina. 
     
     
       3. The composition of claim 2 comprising about 10 wt. % to about 20 wt. % alumina expressed as Al 2  O 3 . 
     
     
       4. The composition of claim 1 wherein said Group IA metal and said Group IIA metal are present in an atomic ratio of about 0.8:1 to about 1.2:2. 
     
     
       5. The composition of claim 1 wherein said composition is additionally substantially free of reducible metal oxide. 
     
     
       6. The composition of claim 1 wherein said Group IA and Group IIA metals have similar ionic radii. 
     
     
       7. The composition of claim 1 wherein said Group IA and Group IIA comprises lithium and said Group IIA metal is selected from the group consisting of magnesium and calcium. 
     
     
       8. The composition of claim 1 wherein said Group IA metal comprises sodium and said Group IIA metal is selected from the group consisting of calcium and strontium. 
     
     
       9. The composition of claim 1 wherein said Group IA metal comprises potassium and said Group IIA metal is selected from the group consisting of calcium, strontium and barium. 
     
     
       10. The composition of claim 1 having a surface area of less than about 25 m 2  /gram. 
     
     
       11. A catalytic composition effective in the conversion of a feedstock alkane containing from 1 to 3 carbon atoms to a higher molecular weight hydrocarbon, said composition prepared according to a method comprising the steps of: thoroughly dispersing in an aqueous medium a mixture comprising a first material comprising a Group IA metal, a second material comprising a Group IIA metal, and a sol comprising an aqueous suspension of a compound of an element selected from the group consisting of aluminum and silicon, to form a slurry, with the combination of said Group IA and said Group IIA metals being selected to be stable at oxidative coupling reaction conditions, and   drying said slurry to evaporate substantially all of said aqueous medium and leaving behind a substantially dry solid material wherein said Group IA metal and said Group IIA metal are in an atomic ratio of about 0.5:1 to about 2:1 and said metal of said sol comprises about 1 wt. % to about 30 wt. % of said dry material.   
     
     
       12. The composition of claim 11 wherein said catalytic composition additionally is substantially free of reducible metal oxide. 
     
     
       13. The composition of claim 11 wherein said Group IA metal comprises lithium and said Group IIA metal is selected from the group consisting of magnesium and calcium. 
     
     
       14. The composition of claim 11 wherein said Group IA metal comprises sodium and said Group IIA metal is selected from the group consisting of calcium and strontium. 
     
     
       15. The composition of claim 11 wherein said Group IA metal comprises potassium and said Group IIA metal is selected from the group consisting of calcium, strontium and barium. 
     
     
       16. The composition of claim 11 having a surface area of less than about 25 m 2  /gram. 
     
     
       17. A catalytic composition effective in the conversion of a feedstock comprising methane to a higher molecular weight hydrocarbon, said composition being substantially free of reducible metal oxide and prepared according to a method comprising the steps of: thoroughly dispersing in an aqueous medium a mixture comprising a first material comprising a Group IA metal, a second material comprising a Group IIA metal, and a sol comprising an aqueous suspension of a compound of an element selected from the group consisting of aluminum and silicon, to form a slurry, with the combination of said Group IA and said Group IIA metals being selected to be stable at oxidative coupling reaction conditions, and   drying said slurry to evaporate substantially all of said aqueous medium and leaving behind a substantially dry solid material wherein said Group IA metal and said Group IIA metal are in an atomic ratio of about 0.5:1 to about 2:1 and said metal of said sol comprises about 1 wt. % to about 30 wt. % of said dry material.   
     
     
       18. The composition of claim 17 wherein said Group IA metal comprises lithium an said Group IIA metal is selected from the group consisting of magnesium and calcium. 
     
     
       19. The composition of claim 17 wherein said Group IA metal comprises sodium and said Group IIA metal is selected from the group consisting of calcium and strontium. 
     
     
       20. The composition of claim 17 wherein said Group IA metal comprises potassium and said Group IIA metal is selected from the group consisting of calcium, strontium and barium.